Polytetrafluoroethylene filamentary material

Abstract: A filamentary material of polytetrafluoroethylene (PTFE) having an apparent density of 2.0 g/cc or more, tensile strength of 5 grams/denier or more, tensile elongation at break of 15% or more, high axial orientation and high crystalline content is disclosed. The filamentary material, when analyzed by differential scanning calorimetry, exhibits two endothermic peaks; the ratio of the energy defined by the higher temperature peak to the energy defined by the lower temperature peak being equal to or greather than 2.

Description: This invention relates to a novel continuous polytetrafluoroethylene fiber having high density and high strength. Polytetrafluoroethylene (PTFE) is well known for its chemical inertness and for its excellent thermal and dielectric properties which make it a desirable material for use in a variety of applications, including many in which it is preferred for use as a fiber, yarn, or other filamentary form. Hereinafter, for convenience, "fiber" may be used to describe filamentary forms in general. Polytetrafluoroethylene fibers have been produced, as described in U.S. Patent No. 3,655,853 (to Gallup), by forming a mixture of viscose and polytetrafluoroethylene particles in a dispersion, extruding the mixture through a spinneret into an acidic bath to form fibers consisting of a cellulosic matrix containing the polytetrafluoroethylene particles. After washing and rinsing, the fibers are heated to a temperature of about 370°C to 390°C to decompose the cellulosic material and to melt and coalesce the polytetrafluoroethylene particles. The fibers are then drawn at a ratio of about 4:1 to 35:1 at a temperature between 370°C and 390°C. The fibers produced by this relatively complex and expensive process have a tensile strength generally less than 2 grams/denier, and may require further processing steps, such as bleaching to remove residual contaminants, which may lower the tensile strength. An improved process is described in U.S. Patent No. 4,064.214 (to Fitzgerald) in which the fibers are further processed through a fibrillating means, such as a high-velocity air jet. Yarns in the 100-2000 denier range having tensile strength in the range 2-6 grams/denier are disclosed. Another method to produce polytetrafluoroethylene fibers is described in U.S. Patent Nos. 3,953,566, 3,962,153 and 4,064,214 (to Gore). In this method a paste formed by mixing a lubricant, such as a mineral spirit, with a fine powder of polytetrafluoroethylene produced by coagulation of an aqueous dispersion of polytetrafluoroethylene particles, is extruded and formed by conventional means to produce a tape or bead. The product thus formed, which may be slit to form fibers, is dried to remove the lubricant and subsequently stretched at a high rate, and at a temperature lower than the crystalline melt point of polytetrafluoroethylene, to produce a porous article. The porous article may then be heated while maintained in the stretched condition to a temperature above the melt point of crystalline polytetrafluoroethylene, generally considered to be in the range 327°C to 345°C to increase strength and dimensional stability. Fibers produced by this method have high tensile strength, typically 2-5 grams/denier and tensile modulus of elasticity in the range 60-180 grams/denier and are essentially contaminant free. The fibers are porous, typically having an apparent density in the range 1.2-1.8 grams/cc. They can, however, have an apparent density as low as about 0.2 grams/cc, as can other porous forms of polytetrafluoroethylene made by the methods described. When analyzed by thermoanalytical methods such as differential scanning calorimetry (DSC), polytetrafluoroethylene articles made by these methods produce thermograms having two endothermic peaks; a higher intensity peak at a temperature of about 342°C±5°C, and a lower intensity peak at a temperature of about 380°C±5°C. Another high temperature process to produce fibers of polytetrafluoroethylene is described in U.S. Patent 5,061,561 (to Katayama). In this method a precursor fiber is prepared in accordance with the methods described in the Gore patents listed above and in Japanese Patent Publication No. 51-18891, and is subsequently stretched in a second stretching step at a temperature higher than the melt point of crystalline polytetrafluoroethylene. The precursor fiber is monoaxially oriented, has an orientation degree of 0.7-0.9, a pore volume of 40-70 percent (corresponding to an apparent density of about 1.21 to 0.69 grams/cc), a tensile modulus of elasticity of about 60-180 grams/denier, and a tensile strength of about 2.8-4.0 grams/denier. The precursor fiber exhibits the characteristic two endothermic peaks of the stretched material, in the intensity relationship described above, at temperatures of 340°C±5°C and 380°C±5°C. The precursor fiber is then generally twisted about 400 to 5000 turns per meter to improve its stability in the second stretching step, and to obtain a finished fiber having a circular cross-section. In the second stretching step the precursor fiber is stretched an amount preferably 2:1 to 6.5:1 at a temperature usually between 360°C and 420°C. In this step the precursor fiber is converted into a finished fiber having the properties: apparent density - 2.15 to 2.3 grams/cc; orientation degree - 0.9 or more; crystalline content 90% or more; tensile strength greater than 5 grams/denier; and tensile modulus of elasticity of 250-350 grams/denier or more. The finished fiber has relatively poor elongation capability. The finished fiber also exhibits the characteristic two endothermic peaks of the stretched material, in the intensity relationship described above, at temperatures of 345°C±5°C and 380°C±5°C. It is an object of the invention to produce a polytetrafluoroethylene fiber having greater elongation capability than the fiber described immediately above without sacrificing other excellent characteristics, and without the need for processing such a fiber at the high temperatures required to exceed the crystalline melt point of polytetrafluoroethylene. According to the present invention, there is provided a filamentary material of polytetrafluoroethylene having an elongation at break of 15 percent or more; said material, when analyzed by differential scanning calorimetry over a temperature range of 30 to 450°C at a heating rate of 10°C/minute, exhibiting a first endothermic peak in the temperature range 325 to 350°C and a second endothermic peak in the temperature range 370 to 390°C; the ratio of the energy defined by said second peak to the energy defined by said first peak being equal to or greater than 2. There may also be provided a filamentary material of polytetrafluoroethylene which comprises polytetrafluoroethylene resin having a standard specific gravity of 2.20 or less. The material may be formed by stretching a precursor fiber having an apparent density of 1.8 grams/cc or less, at a rate of 10%/second or less, at a temperature of 320°C or less. When a material of the present invention is analyzed by thermoanalytical methods a thermogram unlike any previously disclosed is produced. The polytetrafluorotheylene fiber of the invention, when analyzed by differential scanning calorimetry (DSC) at a rate of 10°C/minute over a temperature range of 30°C to 450°C, exhibits two endothermic peaks; one peak having a relatively low intensity in the temperature range 325°C to 350°C, and the second peak having a much higher relative intensity in the temperature range 370°C to 390°C. Specifically, the invention is a filamentary material of polytetrafluoroethylene that, when analyzed by differential scanning calorimetry at a heating rate of 10°C/minute over a temperature range of 30°C to 450°C, exhibits a first endothermic peak in the temperature range 325°C to 350°C and a second endothermic peak in the temperature range 370°C to 390°C; the ratio of the energy defined by the second peak to the energy defined by the first peak equal to or greater than 2 According to a still further aspect of the present invention, there is provided a method of producing a filamentary material having an elongation at break of 15 % or more; said method comprising stretching a precursor fibre of polytetrafluoroethylene at a temperature below the crystalline melt point of polytetrafluoroethylene, said stretching being in an amount of 11:1 or more at a stretch rate of 0.8%/second or more. The method of the present invention may be used to produce a polytetrafluoroethylene fiber that has an apparent density of 2 or more, a degree of orientation of 0.9 or more, a crystalline content of 90 percent or more, a tensile strength of 5 grams/denier or more, and elongation at break of 15 percent or more. Embodiments of the present invention will now be described by way of example, with reference to the accompanying drawing, in which:- Figure 1 is a thermogram obtained by DSC analysis of the fiber of the invention. Figure 2 is a graph representing the relationship between the melt energy ratio and tensile strength of the fiber of the invention. Figure 3 is a graph representing the relationship between the melt energy ratio and elongation at break of the fiber of the invention. The filamentary material of the invention is made by first preparing a precursor fiber according to the methods disclosed in U.S. Patent Nos. 3,953,566, 3,962,153 and 4,064,214 (to Gore). Fine powder polytetrafluoroethylene resin obtained by coagulation of an aqueous dispersion of PTFE particles is mixed with a lubricant, such as kerosene or mineral spirits, to form a paste. The fine powder PTFE resin should preferably be a high molecular weight PTFE resin and have a standard specific gravity (SSG) of 2.2 or less, preferably 2.18 or less; and crystalline content of at least 90 percent, as determined by measurements described hereinbelow. Preferably, the PTFE resin is a homopolymer of tetrafluoroethylene; however, copolymers containing small amounts (no more than 1 mol percent) of another monomer, for example, ethylene, chlorotrifluoroethylene, hexafluoropropylene, perfluoropropyl vinyl ether, etc., may also be used. The mixture is extruded and, optionally, calendered to form a tape. The tape is dried to remove the lubricant and stretched in at least one direction at a temperature of 327°C or less, an amount in the range 1.5:1 to 10:1, preferably in the range 2:1 to 8:1, at a stretch rate of at least 10%/second, and a porous tape having a structure of nodes interconnected by fibrils is obtained. The porous tape may optionally be heated while maintained in the stretched condition, to a temperature higher than the crystalline melt point of polytetrafluoroethylene. The porous tape may then be slit to a desired width to obtain the precursor fiber. The precursor fiber is then subjected to a second stretching step. The second stretching step is also performed at a temperature of 327°C or less, preferably in the range 300°C to 320°C. The stretching rate should be in the range 0.9%/second to 10%/second. The stretch ratio (amount of stretch) should be 25:1 or more, preferably 30:1 or more. If desired, following the second stretching step, the fiber can be heated to a temperature above the PTFE melt point, preferably in the range 350°C to 380°C to improve dimensional stability and reduce subsequent heat shrinkage of the fiber. The second stretching step can be accomplished using conventional methods and equipment. Preferably, the precursor fiber is passed by feed rolls operating at a speed V 1 , and stretched in a heating stretching zone by stretching rolls operating at a speed V 2 >V 1 and taken up at speed V 2 . The heated stretching zone in which the fiber is heated in the range 300°C to 320°C can be a heated platen, an oven, a tube furnace, and the like; or a liquid bath containing molten potassium nitrate, sodium nitrate, sodium nitrite, or other inorganic materials, and the like. Preferably, the heated stretching zone is a heated platen on whose surface the fiber is stretched. Following the second stretching step, the fiber can be given a heat treatment while maintaining the fiber in a stretched condition, at a temperature above the PTFE melt point, preferably in the range 350°C to 380°C. The heat treatment can also be performed using the types of equipment described above. If the heat treatment is performed using such equipment, the speed of the feed rolls and take-up rolls controlling passage of the fiber through the heat treatment zone should be the same speed so that the fiber is prevented from relaxing, and so that further stretching of the fiber is prevented. The stretching rate R st (%/second) and the stretch ratio M st can be expressed by the following equations:- R st ,%/sec. = (V 2 -V 1 /Lx(100/60) M st =V 2 /V 1 where V 1 (meters/minute) is the peripheral speed of the feed roll; V 2 (meters/minute) is the peripheral speed of the stretching roll; and L (meters) is the distance between the feed and stretching rolls. The terms (100/60) are for conversion to %/second. The filamentary material of polytetrafluoroethylene of the invention made as described above has the following properties: apparent density of 2.0 grams/cc or more, preferably 2.2 to 2.3 grams/cc; degree of orientation of 0.90 or more, preferably 0.95 or more; a crystalline content of 90 percent or more, preferably 95 percent or more, tensile strength of 5 grams/denier or more, preferably 6-8 grams/denier, and tensile elongation at break of 15 percent or more, preferably 15-30 percent. The material of the invention is further characterized in that, when analyzed by differential scanning calorimetry at a heating rate of 10°C/minute over a temperature range of 30°C to 450°C, it exhibits a first endothermic peak in the temperature range 325°C to 350°C and a second endothermic peak in the temperature range 370°C to 390°C; the ratio of the energy defined by the second peak to the energy defined by the first peak being equal to or greater than 2. Figure 1 is a thermogram obtained by DSC analysis of a sample of the material of the invention. The curve 1 of the thermogram is the curve representing the quantity of heat absorbed by a sample of the material of the invention when heated at 10°C/minute over the temperature range 30°C to 450°C. The endothermic peak A and endothermic peak B indicate heat absorption attributed to melting of crystalline portions of the sample. It is thought that the lower temperature endothermic peak A is caused by the melting of lamellar crystals present in the node sections of the structure, and the higher temperature endothermic peak B is caused by the melting of extended polymer chain crystals present in the fibril sections of the structure. The areas, S(A) and S(B), under peaks A and B respectively, represent the amount of energy resulting from the crystal melting. The area S(B) defines a melting energy two or more times greater than the melting energy defined by area S(A). The relationship of the energies of melting defined by S(B) and S(A) obtained by DSC analysis are in significant contrast to the relationship of the energies of melting disclosed in USP 5,061,561, in fact, they are in approximately opposite relationship. This clearly indicates that the crystal structure of the material of the invention is significantly different than the crystal structure of the material disclosed in USP 5,061,561. Furthermore, the material of the invention, due to its different crystal structure, has a high tensile strength and markedly greater tensile elongation at break when compared to PTFE fibers formed by stretching at a temperature above 350°C. A relationship has been found between the melt of energy ratio, defined as S(B)/S(A), and tensile properties of the material of the invention. Figure 2 is a graph which illustrates the relationship between the melt energy ratio and tensile strength (grams/denier); and Figure 3 is a graph which illustrates the relationship between the melt energy ratio and tensile elongation at break (%). TEST DESCRIPTIONS Standard Specific Gravity (SSG) Standard Specific Gravity measurements are made according to ASTM Standard D1457. Samples of PTFE resin are compressed in molds and heat treated to produce test billets according to the procedures described in the standard. The test billets, which are essentially void-free, are then used to obtain specific gravity values by liquid displacement methods of density gradient techniques. Specific Gravity was measured by a liquid displacement method using water containing 0.05% TRITON®X-100 wetting agent to lower the surface tension of the water. Apparent Density Apparent density is the weight per unit volume of a material, including voids inherent in the material as tested. It was measured by a liquid displacement method using water containing 0.05% TRITON®X-100 wetting agent to lower the surface tension of the water. Values are reported in grams/cc. Degree of Orientation The degree of orientation is determined by X-ray diffraction measurement of the (100) plane of the PTFE forming the fiber, which is then related to the orientation of the fiber axis. The method is described at page 84 in the Textile Handbook ("Sen'i Binran"), edited by the Society of Textiles ("Sen'i Gakkai"), 3rd Printing (1974), published by Maruzen Co. Crystalline Content The crystalline content of the PTFE is measured by X-ray diffraction techniques. The crystalline content is determined by comparison of the area of the crystallinity peak, which is superimposed on the diffuse amorphous region, to the area of the amorphous region, in the range, diffraction angle 20 = 15° to 25°. Tensile Properties The samples were tested using an Instron Tensile Test Machine in an environment of 25°C and 50% relative humidity. Sample gauge length was 50 mm and crosshead speed was 200 mm/minute. Thermal Analysis The samples were analyzed by differential scanning calorimetry using a Seiko DCS-220 instrument using standard sample preparation procedures. The samples were analyzed over the temperature range 30°C to 450°C at a heating rate of 10°C per minute. The instrumental output included values for the energy of melting defined by the endothermic peaks A and B. A melt energy ratio was calculated from the energy of melting defined by peak A, S(A), and the energy of melting defined by peak B, S(B) as follows: Melt Energy Ratio = S(B)/S(A) The following examples are intended to further describe the invention and should not be construed as limiting the scope of the invention. Example 1 Following the procedures disclosed in U.S. Patent Nos. 3,953,566, 3,962,153 and 4,064,214 a precursor fiber was prepared. PTFE fine powder (crystalline content - 93%; SSG - 2.16) was mixed with kerosene to form a paste and extruded through a die to form a tape. The tape was dried at 200°C to remove the kerosene. The tape was stretched longitudinally an amount of 3:1, at a rate greater than 10%/second, and at a temperature less than 327°C. The stretched tape was then slit to form fibers of 2000 denier to serve as precursor fibers. The precursor fibers had an apparent density of 1.5 grams/cc, degree of orientation of 0.6, crystalline content of 90%, tensile strength of 0.42 grams/denier, tensile elongation at break of 145%, and a melt energy ratio 0.06. The precursor fibers were given a second stretch step under a variety of conditions. The stretching conditions and obtained property values for the samples are shown in Tables 1-3. The precursor fibers were stretched over a heated platen forming a stretching zone between the feed and stretching rolls, which were spaced 1.8 meters apart. The platen surfaces were heated to 300°C, 320°C, or 330°C for the sample runs. The feed rolls were operated at surface speeds (V 1 ) in the range 0.02 to 4 meters/minute; and the stretching rolls were operated at surface speeds (V 2 ) in the range 1 to 91 meters/minute. The stretching rates, R st , and stretch ratios, M st , calculated from the speeds of the sample runs are shown in the tables. After the second stretching step the fibers were immediately fed over a high temperature platen with a surface temperature of 360°C and taken up at a speed V 2 , the same speed at which they were fed onto the high temperature platen. Specimens from each of the sample runs were obtained and were measured to determine tensile properties, apparent density, degree of orientation, crystalline content, and melt energy ratio by the methods described hereinabove. The results are shown in Tables 1-3. Specimens of known length from each of the sample runs were heated to 200°C for 30 minutes in a constant temperature chamber, after which the length of each was remeasured to determine heat shrinkage. In all cases, heat shrinkage was less than 0.5%. It can be seen from Tables 1 to 3 that the stretch ratio (M st ) of the second stretching step must be 25 or more in order to obtain a fiber having a tensile strength of at least 5 grams/denier and an elongation at break of 15% or more. Example 2 A precursor fiber was prepared as described in Example 1, except that it was slit to a size of 3200 denier. The precursor fiber was stretched over a platen heated to 300°C at a stretch ratio of 32:1, and a stretch rate of 8%/second. The fiber was then immediately fed over a high temperature platen (surface temperature - 360°C) and taken up without further stretching. The fiber of the invention obtained in this manner had a size of 100 denier. The fiber was tested as described in Example 1 and found to have the following properties: tensile strength of 6.5 grams/denier, elongation at break of 20%, apparent density of 2.24 grams/cc, degree of orientation of 0.97, crystalline content of 96%, and heat shrinkage less than 0.5%. A sample of the fiber was analyzed by DSC analysis as described above, and produced the thermogram shown in Figure 1. The endothermic peak A reached a maximum at 344°C, and the area under the peak S(A) defined a melt energy of 13.5 mj/mg. The endothermic peak B reached a maximum at 382°C, and the melt energy defined by the area under the peak S(B) was 37.0 mj/mg. The melt energy ratio was 2.74. Example 3 A fiber of the invention was made as described in Example 2, except that the fiber was taken up without passage over the high temperature platen. The fiber was tested as described in Example 2 and found to have similar properties to the fiber of Example 2, except that heat shrinkage was about 5%. Comparative Example 1 A precurser fiber was prepared as described in Example 1, except that the PTFE fine powder had a crystalline content of 92% and SSG of 2.21. The precursor fiber was stretched over a platen heated to 300°C at a stretch ratio of 32:1, and a stretch rate of 8%/second. The fiber was then immediately fed over a high temperature platen (surface temperature - 360°C) and taken up without further stretching. The fiber obtained in this manner was tested and found to have the following properties: tensile strength of 4.5 grams/denier, tensile elongation at break of 6%, apparent density of 2.23 g/cc, degree of orientation of 0.97, crystalline content of 95%, and melt energy ratio of 2.6. The example illustrates the importance of the molecular weight of the PTFE resin starting material. The SSG of the starting resin was higher than 2.20 which is indicative of a molecular weight lower than desired, with the result that a fiber having a tensile strength of 5 grams/denier and tensile elongation at break of 15% or more could not be obtained. Comparative Example 2 Fibers were slit from the extruded and dried tape used to prepare the precursor fibers described in Example 1 before the tape was stretched. The fibers thus obtained were then stretched over a platen heated to 360°C at a stretch rate of 8%/second. The fibers could not be stretched an amount greater than 5:1, and tended to break. Fibers stretched at a stretch ratio of 4:1 had the following properties: tensile strength of 1.2 grams/denier, tensile elongation at break of 60%, apparent density of 1.8 g/cc, degree of orientation of 0.73, crystalline content of 40%, heat shrinkage of 3%, and a melt energy ratio of 0.45. Comparative Example 3 Fibers were prepared as described in Comparative Example 2, except that the platen temperature was 400°C and the stretch rate was 10%/second. The fibers broke at a stretch ratio of 3.

Claims: A filamentary material of polytetrafluoroethylene having an elongation at break of 15 percent or more; said material, when analyzed by differential scanning calorimetry over a temperature range of 30 to 450°C at a heating rate of 10°C/minute, exhibits a first endothermic peak in the temperature range 325 to 350°C and a second endothermic peak in the temperature range 370 and 390°C; and wherein the ratio of the energy defined by said second peak to the energy defined by said first peak being equal to or greater than 2. A filamentary material as claimed in Claim 1 wherein said material has a maximum tensile strength of 5 grams/denier or more. A filamentary material as claimed in any of claims 1 or 2, wherein said material has a degree of orientation of 0.9 or more. A filamentary material as claimed in any of claims 1 to 3 wherein said material has a crystalline content of 90% or more. A filamentary material as claimed in any of claims 1 to 4 wherein said material has an apparent density of 2.0 g/cc or more. A filamentary material as claimed in any of claims 1 to 5 wherein said material comprises polytetrafluoroethylene resin having a standard specific gravity of 2.20 or less, and wherein said material is formed by stretching a precursor fiber having an apparent density of 1.8 grams/cc or less, at a rate of 10%/second or less, at a temperature of 320°C or less. A method of producing a filamentary material having an elongation at break of 15 percent or more; said method comprising stretching a precursor fibre of polytetrafluoroethylene at a temperature below the crystalline melt point of polytetrafluoroethylene, said stretching being in an amount of 11:1 or more, and at a stretch rate of 0.8%/second or more. A method as claimed in claim 7, wherein said stretch rate is in the range of 0.9 to 10%/second. A method as claimed in claim 7 or 8, wherein said stretching is in an amount of 25:1 or more. A method as claimed in any of claims 7 to 9, wherein said filamentary material, when analyzed by differential scanning calorimetry over a temperature range of 30 to 450°C at a heating rate of 10°C/minute, exhibits a first endothermic peak in the temperature range 325 to 350°C and a second endothermic peak in the temperature range 370 and 390°C; and wherein the ratio of the energy defined by said second peak to the energy defined by said first peak being equal to or greater than 2.

Inventors: HIRAI KENGO, HIRAI, KENGO
Applicants: JAPAN GORE TEX INC, JAPAN GORE-TEX, INC.
Application year: 1994
Main classification: D01F6
IPC codes: D01D5, D01F6